&#34;green&#34; temperature-controlled mailer

ABSTRACT

A mailer has an outer, longitudinally extending, biodegradable film with lateral edges folded on itself to form a pocket having an opening and sealable by a flap. An assembly is composed of an inner, longitudinally extending, biodegradable film having lateral edges and a longitudinal extending pad composed of textile cuttings and microbial and superabsorbent powders. The inner film extends longitudinally around the pad and is attached to the pad. The assembly is positioned in the pocket with the inner film being sealed to the outer film adjacent the opening to the pocket trapping the pad between the outer and inner films. Sealing tape is mounted on the inner film adjacent to the pocket to seal the pocket closed. The lateral edges of both the outer and inner films, which extend laterally beyond the pad, are heat sealed together. A container has an outer box an inner insulative layer. The insulative layer is made from flocked textiles and is mixable with absorbatives and antimicrobials.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of International PatentApplication No. PCT/US2009/043972, filed May 14, 2009, which in turnclaimed priority to U.S. patent application Ser. No. 12/120,353, filedMay 14, 2008. The contents of these applications are hereby incorporatedby reference herein in their entirety.

TECHNICAL FIELD

The field of the invention is packaging, in particular, thermallyinsulating packaging and biodegradable packaging.

BACKGROUND ART

The current technology provides paper mailers, lined with plasticbubble-wrap, or more expensive foam, or foam-lined, boxes. Theseproducts are used primarily for shipping sensitive or fragile items, butsuffer from the fact that they have extremely limited cushioning, noabsorption properties, no antimicrobial properties and practically notemperature-control value.

Foam, or foam-lined, boxes are also used for shippingtemperature-sensitive products, such as, medical samples,pharmaceuticals, chocolates, etc. These current products, in addition tobeing dramatically more expensive to purchase, warehouse, and ship(inbound and outbound freight), they are also more labor intensive, lessuser- and environmentally-friendly, and provide very limited protectionduring transit.

The most common thermally insulative material used is Styrofoam.Styrofoam is not biodegradable. Shaped containers (i.e. a Styrofoamcooler) are not collapsible. Shaped containers are more expensive toship than flat boxes because they take more volume. Volume of shippingmaterials correlates to the cost of shipping of the materials.

Styrofoam containers have no absorptive qualities. Likewise, Styrofoamcontainers have no antimicrobial qualities. Accordingly, once acontainer is contaminated, any products subsequently inserted within thecontainer will also become contaminated.

DISCLOSURE OF INVENTION

This application represents the continuing efforts of the Applicantconcerning “green” mailers either with or without temperature controlfor storing and/or shipping temperature-sensitive or perishable goods.Related prior patent applications of Applicant include U.S. ProvisionalPatent Application No. 61/334,797, filed May 14, 2010; U.S. ProvisionalPatent Application No. 61/315,432, filed Mar. 19, 2010; U.S. patentapplication Ser. No. 12/120,353, filed May 14, 2008 (published U.S.Patent Application Publication No. 20090283578); and InternationalPatent Application No. PCT/US2009/043972, filed May 14, 2009 (publishedInternational Application Publication No. WO/2009/140507). Thisapplication also relates to issued U.S. Pat. Nos. 7,229,677; 7,094,192;and 6,875,486. The entirety of the aforementioned patents andapplications are incorporated by reference.

The principal object of the invention is to provide a 100% biodegradabletemperature controlled mailer. In addition, the mailer according to theinvention is user friendly and gusseted.

The novel mailer of the present invention may be used as a stand-aloneshipper, or it may be used as an internal package that maintains aproperly cold temperature in a larger, non-refrigerated box. Savings arerealized from the utilization of the novel mailer of the presentinvention in terms of a) initial cost, as opposed to a foam-lined box;b) set-up/fulfillment labor expenses; c) storage space, with attendantcosts and; d) inbound and out-bound freight charges.

The foregoing is accomplished by a mailer that is composed of materialsthat are biodegradable. The outer surface of the novel mailer consistsof a biodegradable film or paper that is also waterproof. The innersurface of the novel mailer is a biodegradable film or paper (substrate)that is permeable. Sandwiched between the inner biodegradable film orpaper (substrate), and sealed on all sides, is a novel, proprietary,biodegradable, pad made from re-cycled, purified, flocked material (e.g.hollow fibers), to which super absorbent powders (for the absorption ofspills), and antimicrobial powders (for the prevention of contaminationin case of rupture for such products as blood or vaccines, etc.) havebeen added during manufacture. The antimicrobials are programmed toexpire, after a pre-selected desired length of time, to allow for theeventual, natural, degradation/biodegradability of the novel mailer. Theouter surface of the novel pad is encompassed with a waterproof,biodegradable film or paper, sealed on two (or three) sides and isdouble-sealed, with pressure-sensitive, biodegradable tape, at the top,for safety and to prevent tampering. Phase-change materials(refrigerants/gel packs) used in the novel mailer are alsobiodegradable, making the entire shipping system safer, dramaticallymore cost effective, user friendly, environmentally friendly, andsocially responsible.

The novel pad serves six vital purposes: 1) insulation; 2)padding/cushioning; 3) absorption; 4) antimicrobial action; 5)biodegradability; and 6) cost efficiency (in terms of initial cost, asopposed to a foam-lined box, set-up/fulfillment labor expenses, storagespace, with attendant charges, and in-bound and out-bound freightcharges).

The insulative properties of the novel mailer are roughly equivalent toone-half inch of foam, thus, allowing for the savings of second-dayshipping as opposed to the cost of overnight priority freight/deliverycharges as is required with current mailer technology.

A further object of the invention is to provide an entirelybiodegradable, thermally-insulating container. An additional object isto provide a container that is made from as many recycled materials asis possible. An additional object is to provide a container that can beshipped flat to the user and then assembled on site to allow the user tosave in shipping costs.

An object of the invention is to provide a biodegradable, insulativematerial from recycled material that can be shipped in a flat conditionand that has competitive insulative qualities as Styrofoam containers.

An object of the invention is to provide an insulative layer that can beshipped flat and folded to define an air-tight, thermally-insulatedcompartment within the container. The container should be air-tight, bea stand-up container, and have a flap-over lid.

An object of the invention is to provide a container that includes atleast one of the following objects (and preferably as many of theobjects as is possible): 1) insulation, 2) padding/cushioning, 3)absorption, 4) antimicrobial action, 5) biodegradability, and 6) costefficiency.

In accordance with the objects of the invention, a container is providedthat includes two layers: a box and an insulative layer. The boxprovides the general shape of the container when folded. The insulativelayer gives the container improved insulative qualities.

The insulative layer is made from a purified flocked material. Thepurified flocked material is made from recycled textiles. The flockedmaterial is thermally insulating. The flocked material is moldable intodesired shapes. The shapes can be in the form of panels that complementthe interior dimensions of the box. Several panels can be formedtogether. When several panels are joined together, the connectionbetween the panels can be a mitered joint or include scoring tofacilitate the folding of the insulative layer.

In preparing the insulative material, stiffening agents can be added tothe flocked material. Absorptive powders especially those in the classof “super-absorbent powders” can be mixed into the flocked material. Theabsorptive powders wick, absorb, and contain any accidental spills.

Antimicrobials can be mixed into the flocked material. Theantimicrobials mitigate possible contamination and cross-contamination.

Phase-change materials and packages of phase-change materials can beincluded within the container to cool contents within the container.

The insulative layer can be of any desired thickness to provide thedesired insulation amounts. Typical thicknesses are 0.64 cm to 3.8 cm.

Customized logos, printing, and the like can be added to the insulativelayer.

Other and further objects of the present invention will become apparentfrom the following detailed description of the invention when taken inconjunction with the appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagrammatic front perspective view showing a maileraccording to the invention lying flat.

FIG. 2 is a diagrammatic rear perspective view showing the mailer ofFIG. 1 lying flat.

FIG. 3 is a longitudinal sectional view showing the mailer in a prior tofolding and heat sealing.

FIG. 4 is a partial view showing an upper part of the mailer shown inFIG. 3 (the left side as shown), prior to folding and heat sealing,partly broken away to reveal the component parts.

FIG. 5 is a diagrammatic top view of a box in a flat, unfolded position.

FIG. 6 is a diagrammatic side view of a three-segment insert accordingto the invention.

FIG. 7 is a top side view of the three-segment insert shown in FIG. 6.

FIG. 8 is a perspective exploded view of a container with a box in thefolded position with two three-segment inserts in a folded U-shape.

FIG. 9 is a perspective view of the container shown in FIG. 8 with afirst of the two three-segment inserts inserted within the box.

FIG. 10 is a perspective view of a cross-shaped six-panel insert withmitered joints.

FIG. 11 is a perspective view of a cross-shaped six-panel insert withscored joints.

FIG. 12 is an exploded view of a six-panel insert with six separatepanels.

FIG. 13 is top side view of a container with panels adhered to the box,where the box is in an unfolded, flat position.

FIG. 14 is a rear side view of the container shown in FIG. 13.

BEST MODES FOR CARRYING OUT THE INVENTION

Referring now to the drawings, the novel mailer is shown in FIGS. 1 to4. The mailer is composed of materials that are 100% biodegradable. Theouter surface of the novel mailer 10 includes a biodegradable film orpaper 12 that is also waterproof Film 12 extends laterally so itslateral edges or margins 20 can be heat sealed together. At the bottomof the mailer, the film 12 is folded at fold 22. At the top of themailer, the front top edge 28 terminates at the mailer opening 24, andthe back continues upwardly to form flap 26 to enable the mailer 10 tobe sealed by folding the flap 26 over the front of the mailer closingoff the opening 24. The flap 26 has a lateral stripe of adhesive 30covered with a removable protecting paper 32.

The inner surface of the mailer 10 is a biodegradable film or paper(substrate) 14 that is permeable. The inner surface of the mailer 10includes a gusset 23. Sandwiched between the inner biodegradable film orpaper (substrate) 14 and the outer film 12, and sealed on all sides, isa novel, proprietary, biodegradable pad 16 made from recycled, purified,ground material, to which super absorbent powders (for the absorption ofspills), and antimicrobial powders (for the prevention of contaminationin case of rupture for such products as blood or vaccines, etc.) havebeen added during manufacture. The antimicrobials are programmed toexpire, after a preselected desired length of time, to allow for theeventual, natural, degradation/biodegradation of the mailer 10. Theouter surface of the novel pad 16 is encompassed within the water-proof,biodegradable film or paper 12, sealed on two (or three) sides with film14, which extends laterally coextensive with film 12. The film 14 isdouble-sealed, with pressure-sensitive, biodegradable tape 18 (coveredwith a protective strip 34, at the top, for safety and to preventtampering). Film 14 does not surround the pad 16 completely but the endportions 40 extend around a periphery of the pad 16 sufficiently toenable the end portions 40 to be tucked under the bad and sealed withthe film 12, at a joint 44.

As shown in FIG. 4, the film 14 is stitched together with the pad 16 inthe following manner. A row of smaller stitches 50 extend from top tobottom of the mailer 10 along each side thereof juxtaposed adjacent tothe lateral edges 52 of pad 16. Spaced slightly inwardly of stitches 50is a second row of larger stitches 56 that encompass the pad 16 and thefilm 14 on the inside of the pad 16 and include the portions 42 on theoutside of the pad 16. The second rows of stitches only extendlongitudinally from the top of the mailer 10 downwardly and terminatewith the portions 42. Apart from the stitching 50 and 56 and heatsealing of the film 14 to film 12, pad 16 is not attached to film 12.The laid-out mailer shown in FIG. 3 is folded along the dotted line 60to achieve the finished mailer in the manner noted above.

The pad 16, as duly noted, is made from re-cycled, purified, ground-upmaterial, to which super absorbent powders (for the absorption ofspills), and antimicrobial powders (for the prevention of contaminationin case of rupture for such products as blood or vaccines, etc.) havebeen added during manufacture. The antimicrobials are programmed toexpire, after a pre-selected desired length of time, to allow for theeventual, natural, degradation/biodegradability of the novel mailer.

As evident from the above description, the pad 16 is covered by the film14 on the inside with film 14 extending laterally beyond the pad 16 tolie coextensive with the marginal edges of the film 12 so all marginaledges can be heat sealed together. Film 14 extends around thelongitudinal extremities of the pad 16 so that the end portions 40 ofthe film 14 lie between the pad 16 and the outer film 12 when the pad 16is located in the mailer 10. These portions 40 enable the film 14 to beheat sealed together with the film 12 around the mailer opening 24thereby entrapping the pad 16. The portion of the opening 24 that lieswith the flap 26 has the pressure-sensitive, biodegradable tape 18(covered with a protective strip 34) in order to seal the top edges ofthe inner film 14 together before the flap 26 is sealed to the front ofthe mailer 10.

Phase-change materials (refrigerants/gel packs) used in the novel mailerare also biodegradable, making the entire shipping system costeffective, environmentally friendly, and socially responsible.

The novel pad serves six vital purposes: 1) insulation, 2)padding/cushioning, 3) absorption, 4) antimicrobial action, 5)biodegradability, and 6) cost efficiency (in terms of initial cost, asopposed to a foam-lined box, set-up/fulfillment labor expenses, storagespace, with attendant charges, and in-bound and out-bound freightcharges).

The insulation properties of the novel mailer are roughly equivalent to3.81 cm of foam, thus, allowing for the savings of second-day shippingas opposed to the cost of overnight priority freight/delivery charges asis required with current mailer technology.

A specific example of a mailer according to the present invention is onethat is 36.8 cm long, 25 cm wide and has a 11 cm flap. The top openingis about 22 cm across and can be opened to about 13 cm therebyfacilitating loading.

Examples of the materials used for the novel mailer are as follows.Tri-extruded degradable sheeting can be used as a film. The film ismanufactured as 94 cm lay flat at 0.010 cm.

White, opaque tri-extruded degradable sheeting can be used for film 14.The sheeting is manufactured with a degradable additive in all layers.The film manufactured is 30 cm lay flat at 0.0038 cm. For the film 12, awhite opaque outside/silver-color inside triextruded degradable sheetingcan be used. The sheeting is manufactured with a degradable additive inall layers. The film is manufactured as 30 cm lay flat at 0.010 cm. Thefilms are obtainable commercially from a variety of suppliers.

An example of the sealing tape 18 is BP-1052 SIS block co-polymerrubber, obtainable from DarTape Technologies Corporation. Biodegradablematerials are commercially available from ECM Biofilms, Inc.,Painesville, Ohio. Incorporation of at least 1% of the ECM Masterbatchpellets will assure biodegradation. Antimicrobial materials useable areLurol AM-7 obtainable from Goulston Technologies, Inc. of Monroe, N.C.

The pad 16 was made using new textile clippings mixed with commerciallyavailable antimicrobial and super-absorbent powders (such ascarboxymethylcellulose) and then processed through a web formingoperation to produce a pad or batten about 15 mm or 0.6 inches thick.Film 12 can be from about 2 mils thick to about 6 mils thick, andpreferably about 4 mils thick. Film 14 can be from about 0.5 mils thickto about 5 mils thick, and preferably about 3 mils thick. Pad 16 can befrom about 5 mm thick to about 25 mm thick and preferably about 15 mmthick.

FIGS. 5-14 show various embodiments of a biodegradablethermally-insulated container. The embodiments include an outside layerand an inside layer made of thermally-insulative flocked material.

The thermally-insulative flocked material is made from recycledtextiles. The flocked material provides the thermally insulatingproperties to the container. The textiles is purified and then flocked.The textiles are recycled. A biodegradable stiffener is added to theflocked material. The stiffened material is then molded and cut intodesired shapes.

The thermally-insulative material is shipped flat and then assembledwith the container on site. The user of the container saves on inboundshipping of empty containers because the volume consumed by unassembledflat material is much less than the volume of assembled emptycontainers.

FIG. 5 shows a sheet that can be folded into a box 110. The sheetincludes a row of four rectangular segments: front 112, right 114, back113, and left 115. Flaps 111 which will form the top when folded extendfrom a top edge of the row of segments 112, 114, 113, and 115. Flaps 111which will form the bottom when folded extend from a bottom edge of therow of segments 112, 114, 113, and 115. A tab 116 is included on oneedge and is used during assembly of the box 110 from the sheet.

FIGS. 6-7 shows an embodiment of a panel of stiffened flocked materialin the form of a three-segment insert 120. The three-segment insert 120is made from the stiffened flocked material described previously. Thethree-segment insert 120 includes three panels 121, 122, and 121configured in a row. Each segment 121 or 122 is configured to overly arespective inner surface of the box 110. A miter joint 123 is formedbetween each segment 121, 122, and 121.

As shown in FIGS. 8-9, two three segment inserts 120 can be used with abox 110 to form a container 100. First, the box 110 is assembled. Tape117 can be added around the box 110 to secure the box 110 in its foldedshape. Next, a three-segment insert 120 is folded from its unfolded flatform shown in FIGS. 6-7 into a folded U-shaped form shown in FIG. 8. Asshown in FIG. 9, a first folded three-segment insert 120 is insertedinto the box 110. The first leg 121 overlies the right of the box 110.The base 122 overlies the bottom of the box 110. The second leg 121overlies the left of the box 110. The U-shape member is placed with thebase 122 on the bottom of the box 110 to allow a second U-shaped memberto be inserted. Next, as shown in FIG. 8, a second three-segment insert120 is folded into a U-shape and inserted into the box 110. A first leg121 of the second insert 120 overlies a back 113 of the box 110. A top122 of the second insert 120 overlies a top (i.e. folded flaps 111) ofthe box 110. When the two U-shaped members 120 are inserted within thebox 110, an insulated container is formed. The walls of the U-shapedmembers 120 are sized to contact each other to prevent air from beingable to penetrate the insulated layer.

FIGS. 10-11 show two cross-shaped embodiments, which are referred to assix-panel inserts 124, of panels of stiffened flocked material. Thepanels take the form of four panels 125, 130, 126, 129 aligned in acolumn and a row of three panels 126, 127, and 128 (i.e. two laterallyopposed panels 127 and 128 extending from the top and bottom edges ofthe second panel 126 in the column). In the embodiment shown in FIG. 10,the panels 125-130 have miter joints 123 between them. In the embodimentshown in FIG. 11, the panels 125-130 have scores 130 between them toassist in folding.

The embodiment shown in FIGS. 10-11 can be shipped flat (as shown inFIGS. 10-11) to the user. Then, the user can fold the six-panel inserts124 into a box shape. The folded six-panel insert 124 is placed within abox 110. The size of the panels 125-130 are configured to overlapcorresponding panels 111-115 of the box 110.

FIG. 12 shows a six-panel insert 140. The six-panel insert is made fromsix separate panels 125-130. The panels 125-130 correspond to the faces111-115 of a box 110. The panels 125-130 are inserted within the box andoverly the interior of the faces 111-115. The panels 125-130 contacteach other to form an insulated layer and compartment within the box110.

FIGS. 13-14 show an embodiment of a container 100 that ships to the userflat. The box in the flat condition is like the box 110 shown in FIG. 5.Panels 125-130 are formed to complement the sides of the box 110. Thepanels 125-130 have mitered joints. Panels 125-130 are adhered to thefaces 111-115 of the box 110. Glue is an example of a suitable adhesiveto adhere the panels to the box. When the box 110 is folded, the panels125-130 move with the box 110 into engagement with each other to form aninsulated inner layer within the box 110. The inner layer is air-tight.

Although the invention has been described in terms of preferredembodiments, changes can be made which do not depart from the inventiveconcept. Such changes are deemed to fall within the purview of theappended claims.

INDUSTRIAL APPLICABILITY

The mailer and container according to the invention can be applied inthe packaging and shipping industry.

1. A mailer comprising an outer, longitudinally extending, biodegradablefilm having lateral edges folded on itself to form a pocket having anopening and sealable by a flap, and an assembly composed of an inner,longitudinally extending, biodegradable film having lateral edges and alongitudinal extending pad composed of textile cuttings and microbialand super-absorbent powders, with said inner film extendinglongitudinally around the pad and being attached to the pad, saidassemble being positioned in said pocket with said inner film beingsealed to the outer film adjacent the opening to the pocket trapping thepad between the outer and inner films, a sealing tape mounted on theinner film adjacent to the pocket to seal the pocket closed, the lateraledges of both the outer and inner films extending laterally beyond thepad and being heat sealed together.
 2. A mailer according to claim 1wherein the inner film is stitched to the pad adjacent to the heatsealed lateral edges of both the outer and inner films.
 3. A maileraccording to claim 1 wherein the pad is unattached to the outer film. 4.A mailer according to claim 1 wherein the pad is from about 5 mm thickto about 25 mm thick.
 5. A mailer according to claim 4 wherein the padis about 15 mm thick.
 6. A mailer according to claim 1 wherein the outerfilm is from about 2 mils thick to about 6 mils thick.
 7. A maileraccording to claim 6 wherein the outer film is about 4 mils thick.
 8. Amailer according to claim 1 wherein the inner film is from about 0.5mils thick to about 5 mils thick.
 9. A mailer according to claim 8wherein the inner film is about 3 mils thick.
 10. A recyclable shippingcontainer with thermally insulative properties, comprising: a panel ofstiffened flocked material made from textiles mixed with an absorbentand an antimicrobial; and a container holding said panel therewithin.11. The recyclable shipping container according to claim 10, wherein:said container is a box having six sides, said six sides including afront, a back, a right, a left, a top, and a bottom; and said panel is athree-segment insert having three segments in a row and being foldableinto a U-shaped insert, each of said three segments being configured tooverly one of said six sides of said container.
 12. The recyclableshipping container according to claim 11, further comprising a furtherpanel, said panel being a three-segment insert having three segments ina row when unfolded and being foldable into a U-shaped insert, each ofsaid three segment being configured to overly one of said six side ofsaid container not already being overlied.
 13. The recyclable shippingcontainer according to claim 11, wherein said panel is scored betweeneach segment.
 14. The recyclable shipping container according to claim11, wherein said panel has a mitered joint between each panel.
 15. Therecyclable shipping container according to claim 11, wherein: saidcontainer is a box having six sides, said six sides including a front, aback, a right, a left, a top, and a bottom; and said panel is across-shaped six-segment insert having four segments in a column and anadditional segment on each side of said column extending from a secondsegment in said column, each of said six segments being configured tooverly one of said six sides of said container.
 16. A recyclableshipping container with thermally insulative properties, comprising: asheet with four rectangular segments arranged in a row and having a topedge and a bottom edge, and having a top rectangular segment extendingfrom said top edge and a bottom rectangular segment extending from saidbottom edge; and six panels of stiffened flocked material made fromtextiles mixed with an absorbent and an antimicrobial, each of said sixpanels being connected to and overlying a respective one of saidsegments of said sheet; said sheet being foldable into a box with saidsix panels forming an inner layer within said box.
 17. The recyclableshipping container according to claim 16, wherein said sheet iscorrugated cardboard.